Acoustical ceiling construction



Jan. 5, 1965 e. c. ADAMS 3,164,230

ACOUSTICAL CEILING CONSTRUCTION Filed Sept. 4, 1959 IN V EN TOR. 6 a 7'36 6'. fiZa 771s.

United States Patent Ofiice 3,164,230 ACOUSTICAL CEILING CONSTRUCTION George C. Adams, Detroit, Mich., assimior to Rollform, Incorporated, Detroit, Mich., a corporation of Michigan Filed Sept. 4, 1959, Ser. No. 838,098 4 Claims. (Cl. 189-85) This invention relates to new and useful improvements in acoustical ceiling construction.

Acoustical ceilings, comprising preformed perforate sheet metal pans for the support of sound absorbing pads of fibrous material, are widely used in industrial and commercial buildings because of their relatively high acoustical efficiency, relatively low cost, and pleasing appearance. Generally, such pans are secured to a supporting structure that is suspended by suitable hangers from the unfinished superstructure of a room or enclosure.

Installation of the aforementioned type of acoustical ceiling is often difficult when the span of the ceiling is other than a multiple of the dimensions of the preformed metal pans, or when spaces must be provided between adjacent rows of pans to accommodate structural mem bers of the building. This a relatively frequent occurrence because of the multiplicity of construction problems and space requirements that dictate room dimensions.

Heretofore, when the aforementioned condition obtained, it has been necessary to cut and fit the preformed pans of the acoustical ceiling to the required dimension. This expediency has proved to be unsatisfactory because the pans are made from relatively light gauge sheet metal and the cut edges thereof tend to warp or buckle, producing gaps between the pans and adjacent structure. Various other methods of sizing the pans on the job have been tried and have proved to be equally unsuccessful. One practice has been to cut back the side flanges of the pan to form a projecting lip along the cut edge thereof and then bend the lip upwardly by means of a metal break to provide an upstanding stiffening flange. Another has been to nail a support member in the form of a wood block to the cut end of the pan. However, both of these expedients are unsatisfactory because of the time required to effect the sizing and because the finished appearance of the job is often unsatisfactory. Another disadvantage of the aforementioned techniques is that they result in considerable scrap which further increases the cost of the ceiling.

The present invention is directed to an acoustical ceiling construction of the aforementioned character that incorporates a novel means for producing a neat, symmetrical and aesthetically pleasing acoustical ceiling without requiring the sizing of the preformed metal pans on the job. The waste of time and material that has heretofore characterized such installations, due to cutting, bending or blocking of the pans, is eliminated, keeping the total cost of the ceiling to a minimum.

Accordingly, one object of the present invention is to provide an acoustical ceiling construction having a neat, symmetrical and finished appearance.

Another object is to provide an acoustical ceiling construction that satisfies all dimensional conditions encountered on the job.

Another object of the present invention is to provide a ceiling construction that accommodates various dimensions encountered in the spacing of the ceiling panels without requiring the cutting or fabrication of panels on the job.

Another object is to provide a novel ceiling construction including an improved supporting clip.

Other objects and advantages of the present invention will become apparent from the following specification wherein reference is made to the drawings, in which:

FIGURE 1 is a fragmentary perspective view of an 3,164,230 Patented Jan. 5., 1965 acoustical ceiling construction embodying the present invention and illustrating one manner in which the modular pans of the present invention are supported in relation to standard width pans;

FIG. 2 isan enlarged, fragmentary, vertical sectional view of the modular pans of the present invention disposed in parallel relation to a supporting T-bar and secured thereto by a novel spring clip; and

FIG. 3 is an enlarged, fragmentary, vertical sectional view of the modular pan of the present invention shown operatively associated with conventional pans and extending in transverse relation to a T-bar and connected thereto by an improved spring clip.

In accordance with the present invention, a plurality of module strips of various Widths are provided to take care of spacing problems encountered in the installation of an acoustical ceiling. Preferably, the module strips increase in width in relatively small increments, for example in increments of from a 2" width to a 4" width. The module strips are usable in any part of the ceiling, for example at the pilasters of a room or enclosure, at spaced intervals, or along the edges of the room adjacent a wall thereby imparting a balanced, aesthetically pleasing appearance to the acoustical ceiling. The module strips complement and are usable with the standard metal ceiling pans and can be run either parallel or transversely off the supporting T-bars. The module strips may be of any desired length, but are preferably longer than the metal pans, thereby requiring a minimum number of module strips to span a room.

An acoustical ceiling construction embodying the present invention comprises a plurality of preformed metal pans 10, each of which has a flat perforate bottom 11 of generally rectangular configuration and upstanding side flanges 12 and end flanges 14. The lower edges 15 of the pans 10 are beveled to enhance the appearance of the ceiling when the pans 10 are fitted together in edgewise abutting engagement. Preferably, each pan 10 is longer than it is wide, for example twice as long as wide, and the bottom 11, midway between the ends 14 thereof, is provided with a transverse generally V-shaped groove (not shown) which divides the pan into two square areas of equal size.

The pans 10 are preferably supported by a plurality of T-bars 16 that are suspended from a new or existing ceiling (not shown) in spaced parallel relation. An exemplary means of suspending the T-bars 16 is by wire clips 18 that secure the T-bars 16 to a plurality of transverse channels 19 (one of which is shown). The channels 19 are suspended from the superstructure of a room or building (not shown) as by hangers 20.

The T-bars 16 are normally spaced apart a distance equal to the longer dimension of the pans 10 so that the ends 14 thereof are engageable with successive T-bars 16, as will be described. Each T-bar 16 comprises an elongated sheet metal channel member having a substantially flat top surface 21. A pair of longitudinally extending underlying portions 22 and 24 are folded inwardly of the top surface 21 at a re-entrant angle to form a double thickness at the upper outer extremities of the T-bars 16. A pair of angularly related side walls 25 and 26 depend from the underlying portions 22 and 24, respectively. The side walls 25 and 26 are provided with opposed bead portions 28 and 29, respectively, that cooperate to define a generally circular longitudinally extending channel 30 for the acceptance of a complementary bead 31 on the end flanges 14 of the pans 10. The beads 31 on the end flanges 14 of the pans 10 snap into and interlock with the channels 30 of the T-bars 16 to support the pans 10. The beads 28 and 29 terminate in a pair of downwardly extending flanges 32 and 34 that serve to guide the beads 31 on the pans into the channel 30 and function as a positioning means, as will be described.

After the T-bars 16 have been installed, it is necessary only to snap the ceiling pans 10 into place to form the acoustical ceiling. Preferably, before each pan 10 is snapped in place, a sound deadening or insulating pad (not shown) is placed in the pan to enhance the sound absorbing properties of the ceiling.

In accordance with the present invention, spaces of odd dimension between adjacent rows of pans are spanned by a module strip 40. The module strips 40 have a flat bottom face 41 and upturned sides 42 and 44 provided with inturned flanges 45 and 46, respectively.

When a module strip 40 is installed, the bottom face 41 thereof is aligned with the lowermost portion of the upturned side or end flanges 12 and 14, respectively, on the pans 10 so that side portions 42 and 44 of the module strip 40 are not visible. The downwardly extending beveled portions on the pans 10 are completely visible.

When a module strip 40 is disposed in parallel relation to the T-bars 16 (FIG. 2) it is fastened to the T-bars 16 by a plurality of spring clips 50. The clips 50 have a flat top portion 51 with a fold 52 at one end defined by an underlying portion 54 that is folded at a re-entrant angle with respect to the top portion 51. One longitudinally extending top edge of a T-bar 16, defined by the top 21 and one of the folded portions 22 or 24 thereof, is acceptable within the fold 52. The other top edge of the T-bar 16 is caught under a detent 55 in a downwardly extending flange 56 on the other end of the top portion 51 of the clip 50. The clips 50 have a downwardly extending finger 55 with a detent 56 therein for the engagement of the inwardly folded flanges 45 or 46 of the module strips 40.

When a space of odd dimension exists transversely of the T-bars 16, a module strip 40, of appropriate width, is selected to span the space. The module strip 40 is secured to the T-bars 16 by a plurality of springwire clips 60 (one of which is shown). Each clip 60 is of inverted generally U-shaped configuration defined by a bight portion 61 having spaced leg portions 62 and 64 depending therefrom. A pair of fingers 65 and 66 extend outwardly from the lower ends of the leg portions 62 and 64, respectively, and under the inwardly directed flanges 45 and 46, respectively, on the module strip 40 to bias the module strip 40 against the T-bar 16 between the spaced pans 10.

While it will be apparent that the embodiments of the invention herein disclosed are well calculated to fulfill the objects of the invention, it will be appreciated that the invention is susceptible to modification, variation and change Without departing from the proper scope or fair meaning of the subjoined claims:

What is claimed is:

1. An acoustical ceiling construction for a span of ceiling comprising a plurality of rectangular metal pans of predetermined length and width disposed side by side in edgewise abutting engagement, said span being of greater dimension than a whole number multiple of the length or width of said pans, a plurality of elongated channels of generally T-shaped cross-section engageable with said pans for supporting said pans from above, an elongated module strip having a lateral dimension less than the length or width of said pans for completing said s an comprising a flat sheet metal pan having upwardly folded longitudinal edges terminating in re-entrantly folded flanges, said edges being disposed in side by side abutting engagement with aligned ones of said pans and a plurality of spring clips having a flat top surface with means at each end for securing the clips to said channels said clips having a depending resilient finger for engaging one of said flanges to hold said module strip in abutting relationship with said pans.

2. An acoustical ceiling construction for a span of ceiling comprising a plurality of metal pans having predetermined rectangular dimensions disposed side by side in edgewise abutting engagement, said span being of greater dimension than a whole number multiple of either of the dimensions of said pans, a plurality of elongated channels disposed in parallel relationship at a spacing equal to one of the dimensions of said pans for supporting said pans from above, a pair of said channels disposed in parallel relationship at a spacing less than the dimension of said pans, an elongated module strip having a lateral dimension equal to the spacing of said pair of channels for completing said span comprising a flat sheet metal pan having upwardly folded longitudinal edges terminating in re-entrantly folded flanges, said edges being disposed in side by side abutting engagement with aligned ones of said pans, and a plurality of spring clips engageable with said channels and having depending fingers, one of said fingers of each clip respectively engageable with one of said flanges to support said module strip with respect to said pans.

3 An acoustical ceiling construction for a span of ceiling comprising a plurality of rectangular metal pans of fixed length and width disposed side by side in edgewise abutting engagement, said span being of greater dimension than a whole number multiple of the length or width of said pans, means for supporting said pans from above, an elongated module strip having a lateral dimension less than the length or Width of said pans for completing said span comprising a flat sheet metal pan having upwardly folded longitudinal edges terminating in re-entrantly folded flanges, said edges being disposed in side by side abutting engagement with aligned ones of said pans and a plurality of spring clips engageable with and supported by said supporting means and having a pair of depending fingers, one of said fingers of each clip engageable with said flanges, respectively, on said module strip.

4. A spring clip for securing a flanged module strip of an acoustical ceiling to a support structure for said ceiling, said support structure including an elongated memher having spaced edge portions, said clip having a top portion extending transversely of said elongated member with a downwardly extending detent at one end and a reentrant fold at the other end for engaging the spaced edge portions of said elongated member, said clip having a finger depending downwardly from said top portion with a detent at an opposite terminal end therefrom for engagement with the flange on said module strip.

References Cited in the file of this patent UNITED STATES PATENTS 854,209 Goss May 21, 1907 1,838,123 White Dec. 29, 1931 1,997,581 Heeren et al April 16, 1935 2,007,374 Kuehne July 9, 1935 2,112,631 MacDonald Mar. 29, 1938 2,207,454 Brierly July 9, 1940 2,304,480 Schramm Dec. 8, 1942 2,667,667 Jacobson Feb. 2, 1954 2,789,321 Adams Apr. 23, 1957 2,988,184 Zinn June 13, 1961 FOREIGN PATENTS 758,604 Great Britain Oct. 3, 1956 

3. AN ACOUSTICAL CEILING CONSTRUCTION FOR A SPAN OF CEILING COMPRISING A PLURALITY OF RECTANGULAR METAL PANS OF FIXED LENGTH AND WIDTH DISPOSED SIDE BY SIDE IN EDGEWISE ABUTTING ENGAGEMENT, SAID SPAN BEING OF GREATER DIMENSION THAN A WHOLE NUMBER MULTIPLE OF THE LENGTH OR WIDTH OF SAID PANS, MEANS FOR SUPPORTING SAID PANS FROM ABOVE, AN ELONGATED MODULE STRIP HAVING A LATERAL DIMENSION LESS THAN THE LENGTH OF WIDTH OF SAID PANS FOR COMPLETING SAID SPAN COMPRISING A FLAT SHEET METAL PAN HAVING UPWARDLY FOLDED LONGITUDINAL EDGES TERMINATING IN RE-ENTRANTLY FOLDED FLANGES, SAID EDGES BEING DISPOSED IN SIDE BY SIDE ABUTTING ENGAGEMENT WITH ALIGNED ONES OF SAID PANS AND A PLURALITY OF SPRING CLIPS ENGAGEABLE WITH AND SUPPORTED BY SAID SUPPORTING MEANS AND HAVING A PAIR OF DEPENDING FINGERS, ONE OF SAID FINGERS OF EACH CLIP ENGAGEABLE WITH SAID FLANGES, RESPECTIVELY, ON SAID MODULE STRIP. 